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I run the DID 420 Gold race chain on a 1995 Honda CR125 with no issues. I would doubt S.S. will make you Sachs countershaft sprockets...

FYI, the early 1973 250 black center cases are prone to cracking around the right rear cylinder stud if ridden hard.

Start by holding the cutting edge flat against the grinding wheel, with a slight upward tilt to the drill, cutting edge is high end. Lightly grind with out moving bit, then tilt further and spin drill away from cutting edge at the same time, this motion grinds the clearance necessary for a drill to cut. Buy and use a drill guide to check the angles and even out the point. Hope that helps!

When you kick it while trying to start, does the engine "spin", or does it barely turn over once? If the later, lower the compression, add flywheel weight, or go back to a Motoplat. A friend brought a 400 to me that was doing exactly that, started first kick with the Motoplat. Just a thought.

Buchanan's can drill the rims for cross three, and they do have smaller gauge spokes and nipples...

If you buy a Mikuni, I would suggest a 30mm because it shares parts and jets with the 30-34mm carbs, easier to find and more selection. Use a 6F5 needle, I may have other specs if you need. Good luck.

Ignore, ignore, ignore...

I modified and raced a 400 for a few years in AHRMA vintage motocross. Great running and working bike, although I used the shorter wheelbase 175 frame. Your title says 1977 400... by then, the Japanese and the Maico bikes were better developed bikes, in my opinion.

Where are you located Joe? I am experienced with the Sachs motors, but no longer have any parts, so you would have to provide all that is needed.

Cerakote?

From my experience bike needs a title to leave the US. Sold one to Australia, took it apart and shipped as "parts".

Very difficult to install a Mikuni and get an air boot set up. Buy a new needle jet for the Bing, they wear out and it makes the mid range jetting rich. Do the Carl Cranke porting, it will not be doggy!

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DO NOT run a PVL digital on a Sachs motor! I found out the hard way! Engine doesn't rev high enough or quickly enough to make the digital version retard its timing from a very advanced low rpm setting, holed my first piston in two laps!

I would stick with a Motoplat, also less likely to stall. I worked on a friend's 400 and it was impossible to kick it over fast enough to get the PVL to spark, with no added weight. Throw a Motoplat on, started first kick! On my vintage mx race bike with reed valve and more, I added 3 lbs. of brass to the outside of the external Motoplat flywheel to make it rideable.